tailgate DODGE RAM 2003 Service User Guide

TAILGATE
TABLE OF CONTENTS
page page
CHECK CABLE
REMOVAL.............................15
INSTALLATION.........................15
COVER
REMOVAL.............................16
INSTALLATION.........................16
HINGE
REMOVAL.............................16
INSTALLATION.........................16
LATCH
REMOVAL.............................16INSTALLATION.........................16
LATCH STRIKER
REMOVAL.............................17
INSTALLATION.........................17
RELEASE HANDLE/LATCH REMOTE
REMOVAL.............................17
INSTALLATION.........................17
TAILGATE
REMOVAL.............................17
INSTALLATION.........................17
CHECK CABLE
REMOVAL
(1) Open tailgate.
(2) Pry lock tab outward to clear stud head on
cargo box (Fig. 1).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end.
(4) Separate cable end from stud.
(5) Remove screw attaching cable to tailgate. (Fig.
2)
(6) Separate check cable from tailgate.
INSTALLATION
(1) Position check cable on tailgate.
(2) Install bolt attaching small end of cable to tail-
gate.
(3) Tighten tailgate check cable bolt to 23 N´m (17
ft. lbs.).
(4) Position large end of cable onto stud head and
slide downward to secure lock tab.
Fig. 1 Tailgate Check
1 - TAILGATE STRIKER
2 - SCREW DRIVER
3 - TAILGATE CHECK CABLE
4 - LOCK TAB
Fig. 2 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
2 - CONTROL ASSEMBLY
3 - NUTS (2)
4 - TAILGATE
5-LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
DRTAILGATE 23 - 15

COVER
REMOVAL
(1) Open the tailgate.
(2) Remove the eight screws and remove tailgate
liner, if equipped.
(3) Remove the bolts and remove the cover. (Fig. 3)
INSTALLATION
(1) Install the cover and install the bolts and
tighten by hand.
(2) Install the liner and install the screws, if
equipped.
HINGE
REMOVAL
(1) Remove the tailgate. (Refer to 23 - BODY/
TAILGATE/TAILGATE - REMOVAL)
(2) Remove the two screws and remove the hinge/
pivot. (Fig. 4)
INSTALLATION
(1) Install the hinge/pivot and install the screws.
(2) Tighten the screws to 34 N´m (25 ft. lbs.).
(3) Install the tailgate. (Refer to 23 - BODY/TAIL-
GATE/TAILGATE - INSTALLATION)
LATCH
REMOVAL
(1) Remove the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
actuator rod for installation.
(3) Disconnect the actuator rod at the control
assembly. (Fig. 3)
(4) Remove the latch bolt and the check cable bolt.
(Fig. 5)
(5) Remove the latch and actuator rod assembly.
INSTALLATION
(1) Install the latch and actuator rod assembly.
(2) Install the latch and the check cable bolts and
tighten to 23 N´m (17 ft. lbs.).
(3) Connect the actuator rod to the control assem-
bly line up the marks made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
Fig. 3 TAILGATE ASSEMBLY
1 - LATCH ASSEMBLY
2 - CONTROL ASSEMBLY
3 - ACTUATOR ROD (2)
4 - COVER
5 - BOLTS (10)
Fig. 4 TAILGATE HINGE
1 - HINGE/PIVOT
2 - TAILGATE PILLAR
3 - CLIP/BUSHING
4 - BOLTS (2)
23 - 16 TAILGATEDR

LATCH STRIKER
REMOVAL
(1) Open tailgate.
(2) Using a grease pencil or equivalent, mark out-
line of striker on cargo box jamb to aid installation.
(3) Using a Torx drive wrench, remove striker and
washer from cargo box.
INSTALLATION
(1) Position striker and washer on jamb using
alignment outline as reference and install with Torx
drive wrench.
(2) Tighten the striker to 34 N´m (25 ft. lbs.).
RELEASE HANDLE/LATCH
REMOTE
REMOVAL
(1) Remove the tailgate cover. (Refer to 23 - BODY/
TAILGATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
latch actuator rods for ease of installation.
(3) Disconnect the latch actuator rods. (Fig. 3)
(4) Remove the control assembly nuts and remove
the control assembly and the exterior handle. (Fig. 5)
INSTALLATION
(1) Install the handle and the control assembly.
(2) Install the nuts and tighten to 7 N´m (60 in.
lbs.).
(3) Connect the actuator rods using the marks
made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
TAILGATE
REMOVAL
(1) Open the tailgate.
(2) Disconnect the tailgate check cables (Fig. 6).
(Refer to 23 - BODY/TAILGATE/CHECK CABLE -
REMOVAL)
(3) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(4) Slip tailgate hinge collar from pivot pins.
(5) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(6) Separate tailgate from vehicle.
INSTALLATION
(1) Position tailgate collar on left hand pivot pin
and slide tailgate to the left.
(2) Raise tailgate until the notch in the right hand
collar aligns with the pivot pin.
(3) Connect the tailgate check cables. (Refer to 23 -
BODY/TAILGATE/CHECK CABLE - INSTALLA-
TION)
Fig. 5 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
2 - CONTROL ASSEMBLY
3 - NUTS (2)
4 - TAILGATE
5-LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
Fig. 6 TAILGATE ASSEMBLY
1 - LATCH STRIKER
2 - CHECK CABLE BOLT
3 - CHECK CABLE
4 - TAILGATE
5 - HINGE BUSHING
DRTAILGATE 23 - 17

NOTE:
All measurements are in mm.
O/F = Over Flush
U/F = Under Flush
DIMENSION DESCRIPTION GAP FLUSH
1 Tailgate to outer box
(Up/Down surface only)Ð 0.0   1.5
Parallel within 1.0
2 Cab Back to box front 31.0   5.0
Parallel within 3.0Ð
3 Fuel door to outer box 5.0   1.5
Parallel within 1.00.0   1.5
4 Cab to box side 31.0   5.0
Parallel within 3.04.0   2.5 (Standard Cab)
O/F 5.0   2.5 (Quad Cab)
5 Cab to box character line alignment Ð Up/Down 0.0   3.0
6 Tailgate to outer box 5.0   2.0
Parallel within 1.0U/F 1.5   1.5
7 Bumper to outer box 24.75   5.0 (F/A)
23.75   5.0 (C/C)
Parallel within 5.0Ð
8 Tailgate to outer box character line
adjustmentÐ Up/Down 0.0   1.5
9 Bumper to tailgate 30.25   3.0
Parallel within 4.0Ð
Fig. 3 GAP & FLUSH - PICKUP BOX
23 - 98 BODY STRUCTUREDR
GAP AND FLUSH (Continued)

DESCRIPTION FIGURE
REAR ROOF HEADER TO OUTER ROOF PANEL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE81
OUTER BODY SIDE APERTURE TO CAB BACK PANEL TO FLOOR SILL, INNER BODY
SIDE APERTURE TO FLOOR SILL82
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE TO FLOOR SILL 83
REAR FLOOR CROSSMEMBER AND CAB BACK REINFORCEMENT TO CAB BACK
PANEL TO INNER BODY SIDE APERTURE84
CAB BACK REINFORCEMENT TO CAB BACK PANEL 85
CENTER SHOULDER BELT REINFORCEMENT AND TAPPING PLATES TO CAB BACK
REINFORCEMENT86
A-PILLAR REINFORCEMENT TO COWL SIDE PANEL TO OUTER BODY SIDE
APERTURE/APERTURE EXTENSION TO COWL SIDE PANEL87
B-PILLAR REINFORCEMENT TO OUTER ROOF PANEL TO OUTER BODY SIDE
APERTURE88
FRONT ROOF HEADER TO OUTER ROOF PANEL/ROOF BOW TO INNER BODY SIDE
APERTURE/FRONT ROOF HEADER TO A-PILLAR REINFORCEMENT89
INNER BODY SIDE APERTURE TO REAR ROOF HEADER AND OUTER BODY SIDE
APERTURE TO OUTER ROOF PANEL90
FRONT CROSSMEMBER, WHEELHOUSE CROSSMEMBER AND BRACKET SUPPORT
CROSSMEMBER TO BOX FLOOR PAN91
LONG CROSSMEMBER AND FLOOR BOX CROSS SILL TO BOX FLOOR PAN 92
TAPPING PLATES AND SUPPORT BRACKETS TO REAR CROSS BOX SILL, FRONT
WHEELHOUSE, LONG AND BRACKET SUPPORT CROSSMEMBERS93
STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER
BOX SIDE PANEL94
OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE
PANEL MOUNTING95
OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL 96
WELD NUT STRIKER CAGE NUT, OUTER BOX SIDE PANEL AND NUT PLATE TO BOX
SIDE TAILGATE REINFORCEMENT97
FRONT BOX PANEL TO FRONT INNER STAKE POCKET REINFORCEMENT TO FRONT
BOX SIDE PANEL98
FRONT CROSSMEMBER TO FRONT BOX SIDE PANEL AND BOX FLOOR PANEL TO
BOX FRONT PANEL99
BOX FLOOR PANEL AND INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 100
FRONT CROSSMEMBER AND END SUPPORT BRACKET TO LONG CROSSMEMBER
TO INNER BOX SIDE PANEL/STAKE POCKET REINFORCEMENT AND BOX FLOOR
SILL TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR101
STAKE POCKET REINFORCEMENT AND BOX FLOOR SILL CROSSMEMBER TO
INNER TAILGATE PILLAR102
INNER TAILGATE PILLAR PANEL TO INNER BOX SIDE PANEL TO TIE DOWN
MOUNTING REINFORCEMENT103
BOX FLOOR SILL CROSSMEMBER TO INNER BOX SIDE PANEL 104
INNER TAILGATE PILLAR TO TAILGATE BOX SIDE REINFORCEMENT TO OUTER
TAILGATE PILLAR105
BOX SIDE PANEL AND OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 106
FRONT BOX PANEL TO OUTER BOX SIDE PANEL 107
23 - 124 BODY STRUCTUREDR
WELD LOCATIONS (Continued)

DESCRIPTION FIGURE
INNER BOX SIDE PANEL AND INNER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 108
OUTER WHEELHOUSE PANEL TO INNER WHEELHOUSE PANEL 109
FRONT CROSSMEMBER, LONG CROSSMEMBER, AND WHEELHOUSE
CROSSMEMBER TO FLOOR PAN11 0
WHEELHOUSE CROSSMEMBER, LONG CROSSMEMBER AND REAR CROSS BOX
SILL TO BOX FLOOR PAN111
FRONT AND CENTER STAKE POCKET REINFORCEMENTS AND TIE DOWN
MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL11 2
OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT AND OUTER TIE
DOWN MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL11 3
OUTER WHEELHOUSE AND OUTER BRACE MOUNTING REINFORCEMENT TO
OUTER BOX SIDE PANEL11 4
TAILGATE BOX SIDE PIVOT REINFORCEMENT TO OUTER BOX SIDE PANEL 115
FRONT BOX SIDE PANEL TO FRONT CROSSMEMBER TO INNER BOX SIDE PANEL 116
FRONT BOX SIDE PANEL TO BOX FRONT PANEL TO INNER BOX SIDE PANEL/
FRONT STAKE POCKET REINFORCEMENT TO FRONT BOX SIDE PANEL TO BOX
FRONT PANEL11 7
BOX FRONT PANEL TO BOX FLOOR PANEL 118
BOX FLOOR PANEL TO INNER BOX SIDE PANEL 119
LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER
BOX SIDE PANEL120
INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 121
TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER
BOX SIDE PANEL122
REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX SIDE
PANEL123
OUTER BOX SIDE PANEL TO BOX FRONT PANEL AND BOX FRONT SIDE PANEL 124
STAKE POCKET REINFORCEMENTS TO INNER BOX SIDE PANEL TO OUTER BOX
SIDE PANEL125
TAILGATE PIVOT REINFORCEMENT AND INNER TAILGATE PILLAR TO INNER BOX
SIDE PANEL TO OUTER BOX SIDE PANEL126
INNER WHEELHOUSE TO OUTER WHEELHOUSE/TAILGATE PIVOT
REINFORCEMENT TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR127
OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 128
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 129
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 130
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 131
DRBODY STRUCTURE 23 - 125
WELD LOCATIONS (Continued)

Fig. 103 INNER TAILGATE PILLAR PANEL - SHORT CARGO BOX ONLY
23 - 182 BODY STRUCTUREDR
WELD LOCATIONS (Continued)

Fig. 104 BOX FLOOR SILL CROSSMEMBER - SHORT CARGO BOX ONLY
Fig. 105 INNER TAILGATE PILLAR - SHORT CARGO BOX ONLY
DRBODY STRUCTURE 23 - 183
WELD LOCATIONS (Continued)

Fig. 115 TAILGATE BOX SIDE PIVOT REINFORCEMENT - LONG CARGO BOX ONLY
Fig. 116 FRONT BOX SIDE PANEL - LONG CARGO BOX ONLY
23 - 190 BODY STRUCTUREDR
WELD LOCATIONS (Continued)

Fig. 121 INNER WHEELHOUSE PANEL - LONG CARGO BOX ONLY
Fig. 122 TAILGATE PILLAR OUTER PANEL - LONG CARGO BOX ONLY
DRBODY STRUCTURE 23 - 193
WELD LOCATIONS (Continued)